Vertical spiral conveyor

ABSTRACT

The present application discloses vertical spiral conveyors for transporting loose material without the use of vibration or oscillation and methods of transporting materials without the use of vibration or oscillation. In certain embodiments, the vertical spiral conveyor ( 600 ) comprises a vertical spiral fabrication ( 690 ) having a spiral conveyor tray ( 680 ) connected to a vertical member ( 612 ) that is configured to rotate about an axis of rotation ( 670 ), a drive arm ( 660 ) extending from the vertical spiral fabrication ( 690 ), and a drive system for rotating the vertical spiral fabrication ( 690 ) about the axis of rotation ( 670 ). The drive system comprises a power source ( 610 ) and a transmission ( 620 ) coupled to the drive arm ( 660 ). The drive system generates alternating forward and backward strokes on the drive arm ( 660 ) that rotate the vertical spiral fabrication ( 690 ) clockwise and counterclockwise about the axis of rotation to cause loose material to be conveyed around the spiral conveyor tray ( 680 ).

CROSS REFERENCE TO RELATED APPLICATION

This application is a PCT International Patent Application which claimspriority to U.S. Provisional Patent Application No. 61/588,853, filed onJan. 20, 2012 and titled “Vertical Spiral Conveyor,” which is herebyincorporated by reference in its entirety.

BACKGROUND

Known vertical spiral conveyors utilize vibration or mechanicaloscillation of the vertical spiral to move the material. However,vibrating and oscillating conveyors use a lifting and throwing motion tomove the material, which tends to cause breakage, increase of “fine”particles, and separation (e.g., stratification) of fragile product suchas chips and cereals.

SUMMARY

The present application discloses vertical spiral conveyors fortransporting loose material without the use of vibration or mechanicaloscillation and methods of transporting materials without the use ofvibration or oscillation.

In certain embodiments, the vertical spiral conveyor comprises avertical spiral fabrication having a spiral conveyor tray connected to avertical member that is configured to rotate about an axis of rotation,a drive arm extending from the vertical spiral fabrication, and a drivesystem for rotating the vertical spiral fabrication clockwise andcounterclockwise about the axis of rotation. The drive system comprisesa power source and a transmission coupled to the drive arm. The drivesystem generates alternating forward and backward strokes on the drivearm that rotate the vertical spiral fabrication clockwise andcounterclockwise about the axis of rotation to cause loose material tobe conveyed around the spiral conveyor tray.

In certain embodiments, the method comprises utilizing a vertical spiralconveyor to transport materials. The vertical spiral conveyor comprisesa vertical spiral fabrication having a spiral conveyor tray connected toa vertical member that is configured to rotate about an axis ofrotation, a drive arm extending from the vertical spiral fabrication,and a drive system for rotating the vertical spiral fabricationclockwise and counterclockwise about the axis of rotation. The drivesystem comprises a power source and a transmission coupled to the drivearm. The vertical spiral fabrication is rotated clockwise andcounterclockwise about the axis of rotation to cause loose material tobe conveyed around the spiral conveyor tray. The drive system generatesalternating forward and backward strokes on the drive arm that rotatethe vertical spiral fabrication.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic top view illustrating a vertical spiral conveyoraccording to an embodiment of the present application.

FIG. 2 illustrates the speed of rotation of a vertical spiral conveyoraccording to an embodiment of the present application.

FIG. 3 is a perspective view of an exemplary transmission for a verticalspiral conveyor according to an embodiment of the present application.

FIG. 4 is a perspective view of another exemplary transmission for avertical spiral conveyor according to an embodiment of the presentapplication.

FIG. 5 illustrates the speed of rotation of an output shaft of atransmission for a vertical spiral conveyor according to an embodimentof the present application.

FIGS. 6A-6C are perspective, side, and top views, respectively, of anexemplary vertical spiral conveyor according to an embodiment of thepresent application.

FIG. 6D is a top view of an exemplary drive arm of the vertical spiralconveyor of FIGS. 6A-6C.

FIGS. 7A and 7B are top perspective and partial side views of anotherexemplary vertical spiral conveyor according to an embodiment of thepresent application.

FIGS. 8A and 8B show test data in table and graphical form for Cheerios®cereal conveyed using the vertical spiral conveyor shown in FIGS. 6A-6C.

FIGS. 9A and 9B show test data in table and graphical form for SteelChips conveyed using the vertical spiral conveyor shown in FIGS. 6A-6C.

FIGS. 10A and 10B show test data in table and graphical form for SteelChip Balls conveyed using the vertical spiral conveyor shown in FIGS.6A-6C.

FIGS. 11A and 11B show test data in table and graphical form for LaserScrap conveyed using the vertical spiral conveyor shown in FIGS. 6A-6C.

FIGS. 12A and 12B show test data in table and graphical form for CornFlakes® cereal conveyed using the vertical spiral conveyor shown inFIGS. 6A-6C.

FIGS. 13A and 13B are top and bottom perspective views of an exemplarymechanical accumulator of the vertical spiral conveyor shown in FIGS. 7Aand 7B.

DETAILED DESCRIPTION

This Detailed Description merely describes embodiments of the inventionand is not intended to limit the scope of the claims in any way. Indeed,the invention as claimed is broader than and unlimited by the preferredembodiments, and the terms used in the claims have their full ordinarymeaning.

The present application discloses a vertical spiral conveyor. Theconveyor utilizes beltless conveyor technology to move material upwardand around the spiral. A drive system rotates the vertical spiralclockwise and counterclockwise on its vertical axis (e.g., by a fewdegrees) to cause loose material (e.g., bulk powders, metal chips, metalfines, food products, metal sheets, etc.) to be conveyed around thespiral conveyor tray in an upward direction, thus elevating thematerial. In the alternative, the spiral can be driven by the drivesystem to move material downward and around the spiral.

Various advantages of the spiral conveyor include: no vibration; doesnot separate product by size like vibration conveyor; smaller footprintthan a belt conveyor (i.e., takes up less floor space); no belt groovesfor food to get caught, thus it is easier to clean than a belt conveyor;no vibration frequency dead zone (i.e., vibration frequency that doesnot allow material to move on a vibration conveyor); not dependent onweight or density of product like vibrating conveyor; less drivemechanisms than vibrating conveyor (e.g., only 1 drive mechanism isgenerally required, a vibration conveyor generally requires 3 or moredrive mechanisms); lower power consumption than vibrating conveyors(e.g., only about 3 Hp is generally required, a vibration conveyorgenerally requires 30 Hp or more); and others.

FIG. 1 illustrates a vertical spiral conveyor 100 according to anembodiment of the present application. The vertical spiral conveyor 100comprises a vertical spiral fabrication (“VSF”) 190 and a drive systemfor rotating the VSF. The VSF 190 comprises a spiral conveyor tray 180attached via one or more support members 114 to an axial member 112 andis configured to rotate about a vertical axis or axis of rotation 170.The drive system comprises a power source, such as a motor 110, and atransmission or motion transmission box 120. The motor 110 may be avariety of motor types sized to facilitate rotation of the VSF 190, suchas, for example, an electric motor, a variable speed electric motor, orthe like, and may or may not include speed reducer. The output shaft ofthe motion transmission box 120 is coupled via a connecting rod or shaft130 to a drive arm 160 attached to the VSF 190. As shown, the drive arm160 is attached to the axial member 112 of the VSF 190. However, inother embodiments, the drive arm 160 may be attached to other portionsof the VSF 190, such as, for example, the outside of the spiral conveyortray 180.

As illustrated in FIG. 1, the motion transmission box 120 generates aforward stroke and a backward or return stroke in a direction M on theconnecting rod 130, which is tangentially connected to the drive arm 160of the VSF 190. The forward and backward movement of the connecting rod130 and the drive arm 160 causes the VSF 190 to rotate clockwise andcounterclockwise in a direction R about the axis of rotation 170. Themotion transmission box 120 rotates the VSF 190 clockwise andcounterclockwise on its vertical axis (e.g., by a few degrees) to causeloose material (e.g., bulk powders, metal fines, metal sheets, metalchips, food products, etc.) to be conveyed around the spiral conveyortray 180 in an upward direction, thus elevating the material.

In certain embodiments, the VSF 190 rotates between about 2 degrees andabout 10 degrees about the axis of rotation 170 during each forward andbackward stroke. However, the amount of rotation may depend on a varietyof factors, including the diameter of the VSF 190. For example, incertain embodiments, the diameter of the VSF 190 is about 120 inches andthe VSF rotates about 3 degrees about the axis of rotation 170 duringeach forward and backward stroke. In certain embodiments, the diameterof the VSF 190 is about 96 inches and the VSF rotates about 4 degreesabout the axis of rotation 170 during each forward and backward stroke.In certain embodiments, the diameter of the VSF 190 is about 40 inchesand the VSF rotates about 9 degrees about the axis of rotation 170during each forward and backward stroke.

FIG. 2 illustrates the speed of rotation of the VSF 190 during theforward and return stroke of the connecting rod 130 and the drive arm160. As shown, during the forward stroke, the speed of the rotation ofthe VSF 190 accelerates slowly (A_(F)) to a maximum forward speed (MaxS_(F)) and decelerates suddenly (D_(F)) to zero. This causes thematerial on the spiral conveyor tray 180 to slide forward (when viewedfrom the proximal side) and up around the spiral. Momentum of thematerial may propel the material further after motion of the connectingrod 130 and VSF 190 suddenly stop. During a first portion of the returnstroke of the connecting rod 130 and the drive arm 160, the speed of therotation of the VSF 190 accelerates quickly (A_(R)) to a maximum returnspeed (Max S_(R)) causing the spiral conveyor tray 180 to slide fromunder the material without causing much backward motion of the materialas the connecting rod and VSF are repositioned in anticipation of thenext forward stroke of the shaft. During a second portion of the returnstroke, the speed of the rotation of the VSF 190 decelerates slowly(D_(R)) to zero without causing much backward motion of the material onthe spiral conveyor tray 180. This cycle is repeated such that theproduct moves up and around the spiral conveyor tray 180 to the top ofthe system.

In certain embodiments, the maximum forward speed (Max S_(F)) and themaximum return speed (Max S_(R)) of the VSF 190 is between about 1300feet per minute (fpm) and about 1600 fpm, between about 1400 fpm andabout 1500 fpm, greater than about 1300 fpm, greater than about 1400fpm, greater than about 1450 fpm, about 1400 fpm, about 1450 fpm, andabout 1470 fpm when the motor 110 input speed is about 70 RPM. Incertain embodiments, the VSF 190 may only reach the maximum speed (MaxS_(R) or Max S_(F)) during about ¼ inch or less of the forward or returnstroke. During the remainder of the stroke, the VSF 190 is acceleratingup to this speed or decelerating.

The connecting rod 130 may be coupled to the drive arm 160 at a varietyof locations along the length of the drive arm. Furthermore, couplingthe connecting rod 130 closer to the vertical axis or axis of rotation170 of the VSF 190 increases the amount the spiral conveyor tray 180moves or rotates during the forward and backward stroke of theconnecting rod. For example, as illustrated in FIG. 1, the amount ofmovement of the spiral conveyor tray 180 is greater when the connectingrod 130 is coupled to the drive arm 160 at a distance R₁ from the axisof rotation 170 when compared to the distance R₂ or the distance R₃. Incertain embodiments, the connecting rod 130 is coupled to the drive arm160 between about 15 inches and about 30 inches from the axis ofrotation 170 and the spiral conveyor tray 180 moves between about 2.5inches and about 6 inches during each forward and backward stroke. Inone embodiment, R₁ is about 16 inches and the corresponding amount ofmovement of the spiral conveyor tray 180 during the forward stroke orbackward stroke of the connecting rod 130 is about 6 inches. In anotherembodiment, R₂ is about 26 inches and the corresponding amount ofmovement of the spiral conveyor tray 180 during the forward stroke orbackward stroke of the connecting rod 130 is about 2.9 inches. In yetanother embodiment, R₃ is about 30 inches and the corresponding amountof movement of the spiral conveyor tray 180 during the forward stroke orbackward stroke of the connecting rod 130 is about 2.6 inches. As such,the spiral conveyor 100 permits the amount of movement of the spiralconveyor tray 180 during the forward stroke or backward stroke of theconnecting rod 130 to be adjusted by changing the coupling point of theconnecting rod and the drive arm 160.

The VSF 190 and/or the spiral conveyor tray 180 may be various sizes andthe size of the spiral conveyor 100 components may depend on a varietyof factors, including the type or amount of material conveyed, therequired elevation change, or space constraints. For example, asillustrated in FIG. 1, the outer diameter D₁ of the VSF 190 or thespiral conveyor tray 180 may be between about 50 and 120 inches, lessthan 60 inches, about 60 inches, greater than 60 inches, less than 72inches, about 72 inches, greater than 72 inches, about 4 feet, about 5feet, about 6 feet, about 7 feet, about 8 feet, about 9 feet, about 10feet, or virtually any other diameter. Further, the inner diameter D₂ ofthe spiral conveyor tray 180 may be between about 30 and 72 inches, lessthan 36 inches, about 36 inches, greater than 36 inches, less than 48inches, about 48 inches, greater than 48 inches, or virtually any otherdiameter. Still further, the width of the spiral conveyor tray 180 maybe between about 6 and 36 inches, less than 12 inches, about 12 inches,greater than 12 inches, less than 18 inches, about 18 inches, greaterthan 18 inches, less than 24 inches, about 24 inches, greater than 24inches, or virtually any other width.

As illustrated in FIG. 1, the spiral conveyor 100 may include asuspension unit 140 coupling the connecting rod 130 to the drive arm160. The suspension unit 140 may facilitate coupling of the systemcomponents and the absorption of vibration. The suspension unit 140 mayalso reduce the stresses on the system components, reduce wear andincrease the life of the components.

FIGS. 7A and 7B illustrate a vertical spiral conveyor 700 according toan embodiment of the present application. The vertical spiral conveyor700 comprises a frame 714, a vertical spiral fabrication (“VSF”) 790,and a drive system for rotating the VSF relative to the frame. The VSF790 comprises a spiral conveyor tray 780 attached via one or moresupport members to an axial member 712 and is configured to rotate abouta vertical axis or axis of rotation 770. The drive system comprises amotor 710 and a transmission or motion transmission box 720. The motor710 may be a variety of motor types sized to facilitate rotation of theVSF 790, such as, for example, an electric motor, a variable speedelectric motor, or the like, and may or may not include speed reducer.The output shaft of the motion transmission box 720 is coupled via aconnecting rod or shaft 730 to a drive arm (not shown) attached to theVSF 790. The drive arm is attached to the axial member 712 of the VSF790. However, in other embodiments, the drive arm may be attached toother portions of the VSF 790, such as, for example, the outside of thespiral conveyor tray 780. As illustrated in FIGS. 7A and 7B, thevertical spiral conveyor 700 comprises a suspension unit 716 couplingthe connecting rod 730 to the drive arm. As shown, the suspension unit716 is a ROSTA rubber suspension unit, for example a type ST 80 DriveHead.

Referring again to FIG. 1, the spiral conveyor 100 may also include oneor more mechanical accumulators attached between the rotating VSF 190 ordrive arm 160 and a frame of the spiral conveyor. As shown, a mechanicalaccumulator 150 is attached at a first end to the drive arm 160 and asecond end to a frame (not shown) of the spiral conveyor 100. However,in other embodiments, more or less mechanical accumulators may beattached to the rotating VSF 190 or drive arm 160 of the spiral conveyor100. The mechanical accumulator 150 may be configured to assist and/orresist the rotation of the VSF 190 or movement of the drive arm 160during the forward and/or backward stroke of the connecting rod 130. Assuch, the mechanical accumulator 150 reduces the stresses on the systemcomponents, reduces wear and increases the life of the components.Furthermore, the mechanical accumulator 150 may be configured tocomplement or assist the motion of the VSF 190 or drive arm 160 suchthat a smaller motor 110 may be used with the system to achieve adesired or specified motion of the VSF 190, therefore reducing theenergy consumption of the spiral conveyor 100.

As illustrated in FIGS. 7A and 7B, the vertical spiral conveyor 700comprises a mechanical accumulator 718 having a first end attached to adrive arm and a second end attached to a frame 714 of the verticalspiral conveyor. FIGS. 13A and 13B illustrate the mechanical accumulator718 of the vertical spiral conveyor 700. As shown, the accumulator 718comprises four accumulator portions, a first portion 1302 pivotallycoupled to a second portion 1304 by a rocker arm 1310 and a thirdportion 1306 pivotally coupled to a fourth portion 1308 by a rocker arm1310. The second portion 1304 and the third portion 1306 share a commonhousing and are fixed relative to one another. The first portion 1302 iscoupled to the drive arm of the vertical spiral conveyor 700 and thefourth portion 1308 is coupled to the frame 714 of the vertical spiralconveyor. The accumulator 718 is configured such that the first andfourth portions 1302 and 1308 move relative to one another and pivotrelative to the second and third portions 1304 and 1306 to assist and/orresist the movement of the drive arm relative to the frame 714 of thevertical spiral conveyor 700. As such, the accumulator 718 may beconfigured to assist and/or resist the rotation of the VSF 790 ormovement of the drive arm during the forward and/or backward stroke ofthe connecting rod 730. As shown, the mechanical accumulator 718 is aROSTA rubber accumulator, for example a type AB 50-2 spring accumulator.However, other mechanical accumulators capable of assisting and/orresisting the rotation of the VSF 790 or movement of the drive armduring the forward and/or backward stroke of the connecting rod 730 maybe used.

In certain embodiments, the motion transmission box 120 of the spiralconveyor 100 is a differential motion transmission box or “ShuffleDrive” similar to that described in U.S. Pat. Nos. 6,415,912 and6,634,488, both of which are incorporated herein by reference in theirentirety. FIGS. 3 and 4 of the present application illustrate twoembodiments of a shuffle drive, either of which may be used in the drivesystem of the spiral conveyors of the present application.

As illustrated in FIG. 3, the shuffle drive or driving apparatus 300comprises a cam 322 rotated by a drive shaft 340 and a follower 326having a slot 324 formed therein for receipt of the cam. As the cam 322rotates, it rolls backwards and forwards in the slot 324 and impartsrotation to the follower 326. A connecting or output shaft 328 isaffixed to the follower 326 and is rotated thereby. The connecting shaft328 has an axis of rotation parallel to, but offset from, the axis ofrotation of the drive shaft 340. A crank 332 is affixed to theconnecting shaft 328 and is operatively connected to the spiral conveyortray for imparting reciprocating motion to the tray.

As illustrated in FIG. 4, the shuffle drive or driving apparatus 400comprises a drive shaft 440 affixed to a rotating driving block ormember 442. A link 444 is rotatably mounted in bearings to the block torotate about axis 444 a. The link 444 is also rotatably mounted inbearings to a driven block or member 450 to rotate about an axis 448 a.A connecting or output shaft 452 is affixed to the driven block 450. Theaxis of rotation 444 a of the link 444 is offset from the axis ofrotation of drive shaft 440 and the axis of rotation of the connectingshaft 452 is also offset from the axis of rotation of the drive shaft. Acrank 432 is affixed to the connecting shaft 452 and is operativelyconnected to the spiral conveyor tray for imparting reciprocating motionto the tray.

The shuffle drives 300 and 400 are configured to impart similarreciprocating motion to the spiral conveyor tray. As such, coupling thecrank 332 and 432 of the shuffle drives 300 and 400 to the VSF 190 ofthe spiral conveyor 100 will generate the motion of the VSF describedabove and shown in FIG. 2, which illustrates the speed of rotation ofthe VSF during the forward and backward stroke of the connecting rod 130and the drive arm 160.

FIG. 5 illustrates the speed of rotation of the connecting or outputshaft 328 of the shuffle drive 300 and the connecting or output shaft452 of the shuffle drive 400 for one revolution of the shaft. As shown,the connecting shaft 328 and 452 rotates from 0-180 degrees during theforward stroke of the connecting rod 130 of the spiral conveyor 100 andfrom 180-360 degrees during the backward or return stroke of theconnecting rod 130. The connecting shaft 328 and 452 graduallyaccelerates from a minimum rotation speed S_(min) to a maximum rotationspeed S_(max) between 0 and about 120 degrees, 120 degrees+/−5 degreesor at about 123 degrees in one specific embodiment. The connecting shaft328 and 452 then quickly decelerates from the maximum rotation speedS_(max) to the minimum rotation speed S_(min) between about 120 degreesand 180 degrees. The connecting shaft 328 and 452 then quicklyaccelerates again from the minimum rotation speed S_(min) to the maximumrotation speed S_(max) between 180 and about 240 degrees, 240degrees+/−5 degrees or at about 237 degrees in one specific embodiment.The connecting shaft 328 and 452 then gradually decelerates from themaximum rotation speed S_(max) to the minimum rotation speed S_(min)between about 240 degrees and 360 degrees.

The values for S_(min) and S_(max) of the connecting shaft 328 and 452will vary depending on the rotation speed S_(drive) of the drive shaft340 and 440 of the shuffle drive 300 and 400, which is coupled to themotor of the vertical spiral conveyor. For example, the minimum rotationspeed S_(min) of the connecting shaft 328 and 452 will range betweenabout 30 RPM and about 60 RPM for rotation speeds S_(drive) of the driveshaft 340 and 440 between about 45 RPM and about 85 RPM. Also, themaximum rotation speed S_(max) of the connecting shaft 328 and 452 willrange between about 80 RPM and about 145 RPM for rotation speedsS_(drive) of the drive shaft 340 and 440 between about 45 RPM and about85 RPM. The table below includes approximate values for S_(min) andS_(max) of the connecting shaft 328 and 452 for given rotation speedsS_(drive) of the drive shaft 340 and 440 of the shuffle drive 300 and400, which is coupled to the motor of the vertical spiral conveyor.

S_(drive) (RPM) +/− S_(min) (RPM) +/− S_(max) (RPM) +/− S_(drive)(Hertz) 3 RPM 3 RPM 3 RPM 40 46 32 81 50 58 40 102 60 70 48 123 70 81 56143

Rapid, sudden, or quick deceleration of the connecting shaft 328 and 452occurs when the rotation speed of the shaft decreases from the maximumrotation speed S_(max) to the minimum rotation speed S_(min) in about 60degrees of rotation of the shaft, or between about 50 degrees and about70 degrees of rotation of the shaft. For example, in certainembodiments, the connecting shaft 328 and 452 will quickly deceleratefrom about 143 RPM to about 56 RPM in about 60 degrees of rotation ofthe shaft. Further, rapid, sudden, or quick acceleration of theconnecting shaft 328 and 452 occurs when the rotation speed of the shaftincreases from the minimum rotation speed S_(min) to the maximumrotation speed S_(max) in about 60 degrees of rotation of the shaft, orbetween about 50 degrees and about 70 degrees of rotation of the shaft.For example, in certain embodiments, the connecting shaft 328 and 452will quickly accelerate from about 56 RPM to about 143 RPM in about 60degrees of rotation of the shaft.

Gradual or slow acceleration of the connecting shaft 328 and 452 occurswhen the rotation speed of the shaft increases from the minimum rotationspeed S_(min) to the maximum rotation speed S_(max) in about 120 degreesof rotation of the shaft, or between about 110 degrees and about 130degrees of rotation of the shaft. For example, in certain embodiments,the connecting shaft 328 and 452 will gradually accelerate from about 56RPM to about 143 RPM in about 120 degrees of rotation of the shaft.Gradual or slow deceleration of the connecting shaft 328 and 452 occurswhen the rotation speed of the shaft decreases from the maximum rotationspeed S_(max) to the minimum rotation speed S_(min) in about 120 degreesof rotation of the shaft, or between about 110 degrees and about 130degrees of rotation of the shaft. For example, in certain embodiments,the connecting shaft 328 and 452 will gradually decelerate from about143 RPM to about 56 RPM in about 120 degrees of rotation of the shaft.

The connecting shaft 328 and 452 gradually accelerates from a minimumrotation speed S_(min) to a maximum rotation speed S_(max) between 0 andabout 120 degrees, 120 degrees+/−5 degrees or at about 123 degrees inone specific embodiment. The connecting shaft 328 and 452 then quicklydecelerates from the maximum rotation speed S_(max) to the minimumrotation speed S_(min) between about 120 degrees and 180 degrees. Theconnecting shaft 328 and 452 then quickly accelerates again from theminimum rotation speed S_(min) to the maximum rotation speed S_(max)between 180 and about 240 degrees, 240 degrees+/−5 degrees or at about237 degrees in one specific embodiment. The connecting shaft 328 and 452then gradually decelerates from the maximum rotation speed S_(max) tothe minimum rotation speed S_(min) between about 240 degrees and 360degrees.

FIGS. 6A-6D illustrate a vertical spiral conveyor 600 according to anembodiment of the present application. The vertical spiral conveyor 600comprises a frame 692, a vertical spiral fabrication (“VSF”) 690, and adrive system for rotating the VSF. The VSF 690 comprises a spiralconveyor tray 680 attached via one or more support members 614 to anaxial member 612. The frame 692 is configured to support the VSF 690 andfacilitate rotation of the VSF about a vertical axis or axis of rotation670. As shown, the frame 692 supports the axial member 612 of the VSF690 and bearings permit rotation of the axial member relative to theframe. However, in other embodiments, the VSF may be supported on one ormore sides by the frame in lieu of or in addition to being supported byan axial member. Further, for the purposes of clarity, only a littlemore than one 360 degree portion of the spiral conveyor tray 680 isshown. However, it should be understood that the vertical spiralconveyor 600 may be any length, have various angular portions, and/orelevate material various vertical distances.

The drive system of the vertical spiral conveyor 600 comprises a motor610 and a transmission or a motion transmission box 620. The output ofthe motion transmission box 620 is coupled via a connecting rod or shaft630 to a drive arm 660 attached to the VSF 690. As shown, the drive arm660 is attached to the axial member 612 of the VSF 690. However, inother embodiments, the drive arm 660 may be attached to other portionsof the VSF 690, such as, for example, the outside of the spiral conveyortray 680. The motor 610 of the vertical spiral conveyor 600 may be avariety of motor types sized to facilitate rotation of the VSF 690, suchas, for example, an electric motor, a variable speed electric motor, orthe like, and may or may not include a speed reducer. As illustrated inFIGS. 6A-8B, the motor 610 is a variable speed 1 Hp Sumitomo 6100gearmotor with a 25:1 speed reducer. Furthermore, the motiontransmission box 620 of the spiral conveyor 600 comprises a shuffledrive as described above with reference to FIGS. 3 and 4 and/or asdescribed in U.S. Pat. Nos. 6,415,912 and 6,634,488.

The motion transmission box 620 is configured to generate a forwardstroke and a backward or return stroke on the connecting rod 630, whichis tangentially connected to the drive arm 660 of the VSF 690. Theforward and backward movement of the connecting rod 630 and the drivearm 660 causes the VSF 690 to rotate clockwise and counterclockwiseabout the axis of rotation 670. The motion transmission box 620 rotatesthe VSF 690 clockwise and counterclockwise on its vertical axis (e.g.,by a few degrees) to cause loose material (e.g., bulk powders, metalfines, metal chips, metal plates, food products, etc.) to be conveyedaround the spiral conveyor tray 680 in an upward direction, thuselevating the material. Furthermore, the motion of the VSF 690 is thesame as described above in reference to VSF 190 and shown in FIG. 2,which illustrates the speed of rotation of the VSF during the forwardand backward stroke of the connecting rod.

The pitch of the spiral conveyor tray 680 (i.e., the rise of theconveyor tray for a 360 degree portion of the conveyor tray) may be avariety of distances, such as, for example, between about 3 and 12inches, less than 8 inches, about 8 inches, greater than 8 inches, about5 inches, about 6 inches, about 7 inches, about 8 inches, about 9inches, about 10 inches, or virtually any other distance. Furthermore,the pitch of the spiral conveyor tray 680 may be adjusted. For example,adjusting the support members 614 relative to the axial member 612changes the pitch of the spiral conveyor tray 680, such as, for example,adjusting the length and/or vertical position of one or more supportmembers relative to the axial member. As illustrated in FIGS. 6A and 6B,the pitch of the spiral conveyor tray 680 is about 8 inches for a 360degree portion or segment of the conveyor tray.

As illustrated in FIGS. 6A-6D, the drive arm 660 of the vertical spiralconveyor 600 comprises one or more openings or connection points 662 forthe connecting rod 630. As described above in reference to verticalspiral conveyor 100, coupling the connecting rod 630 closer to thevertical axis or axis of rotation 670 of the VSF 690 increases theamount the spiral conveyor tray 680 moves or rotates during the forwardand backward stroke of the connecting rod. As such, the spiral conveyor600 permits the amount of movement of the spiral conveyor tray 680during the forward stroke or backward stroke of the connecting rod 630to be adjusted by coupling the connecting rod to the drive arm 660 atone of the variety of connection points 662.

The vertical spiral conveyor 600 was tested with five different loosematerials—Cheerios® cereal, Steel Chips (curled steel shavings), SteelChip Balls (spiral steel shavings), Laser Scrap (flat metal pieces ofvarious sizes), and Kellogg's Corn Flakes® cereal. Although no testswere run with potato chips, it is expected that tests with potato chipswould result in similar values as the tests with Corn Flakes® cereal.The test results are shown in: FIGS. 8A and 8B for the Cheerios® cereal;FIGS. 9A and 9B for the Steel Chips; FIGS. 10A and 10B for the SteelChip Balls; FIGS. 11A and 11B for the Laser Scrap; and FIGS. 12A and 12Bfor the Corn Flakes® cereal.

As can be seen in the test results, the same set of tests were run foreach of the different materials. In a first set of tests, the connectingrod 630 was coupled to drive arm 660 of the vertical spiral conveyor 600at a first or inner stroke position, which is referenced in thespreadsheet and graphs as “Pos. 1”. In the first position, theconnecting rod 630 is coupled to the drive arm 660 approximately 16inches from the vertical axis or axis of rotation 670 of the verticalspiral conveyor 600. In this position, the spiral conveyor tray 680moves approximately 6 inches during the forward stroke or backwardstroke of the connecting rod 630. Four tests were run with theconnecting rod 630 in the first position varying the motor 610 speed—40Hz (46 Strokes/Minute), 50 Hz (58 Strokes/Minute), 60 Hz (70Strokes/Minute), and 70 Hz (81 Strokes/Minute). For the purpose of thesecalculations, one stroke is one complete cycle (one forward and onereturn stroke of the connection rod 630 and the drive arm 660).

The same set of tests varying the motor speed were run with theconnecting rod 630 in a second or middle stroke position (“Pos. 2”) anda third or outer stroke position (“Pos. 3”). In the second position, theconnecting rod 630 is coupled to the drive arm 660 approximately 26inches from the vertical axis or axis of rotation 670 of the verticalspiral conveyor 600 and the spiral conveyor tray 680 moves approximately2.9 inches during the forward stroke or backward stroke of theconnecting rod. In the third position, the connecting rod 630 is coupledto the drive arm 660 approximately 30 inches from the vertical axis oraxis of rotation 670 of the vertical spiral conveyor 600 and the spiralconveyor tray 680 moves approximately 2.6 inches during the forwardstroke or backward stroke of the connecting rod. In all the tests, thepitch of the spiral conveyor tray 680 was about 8 inches for a 360degree portion or segment of the conveyor tray.

During the tests, the amount of time for the material to travel 180degrees about the spiral conveyor tray 680 was measured for each test(“Time for 180 Degrees”). This time was measured for material at: theinside edge of the 12 inch wide spiral conveyor tray 680 which isapproximately 18 inches from the vertical axis or axis of rotation 670(“@ 18” Radius” or “18”); the middle line of the spiral conveyor traywhich is approximately 24 inches from the vertical axis or axis ofrotation (“@ 24” Radius” or “24”); and the outside edge of the spiralconveyor tray which is approximately 30 inches from the vertical axis oraxis of rotation (“@ 30” Radius” or “30”). Furthermore, the speed of thematerial (“Calculated Speed Feet Per Minute @ Radius”) at the insideedge, middle line, and outside edge of the spiral conveyor tray 680 wascalculated in feet/minute using the Time for 180 Degrees. These threespeeds were then averaged for each test (“Average Speed”). FIGS. 8A, 9A,10A, 11A, and 12A show the Calculated Speed and Average Speed for eachtest. The results of the tests described above are also presented ingraphical form in FIGS. 8B, 9B, 10B, 11B, and 12B. In these graphs, theAverage Speed of the material is plotted against motor speed for eachposition of the connecting rod 630.

As illustrated in FIGS. 8A and 8B, the vertical spiral conveyor 600 iscapable of conveying Cheerios® cereal upward around the spiral conveyortray 680 at an average speed of greater than 30 feet per minute (fpm),greater than 35 fpm, greater than 40 fpm, greater than 45 fpm, greaterthan 50 fpm, greater than 55 fpm, between about 30 fpm and about 55 fpm,between about 40 fpm and about 55 fpm, and about 56 fpm.

As illustrated in FIGS. 12A and 12B, the vertical spiral conveyor 600 iscapable of conveying Kellogg's Corn Flakes® cereal upward around thespiral conveyor tray 680 at an average speed of greater than 30 fpm,greater than 35 fpm, greater than 40 fpm, greater than 45 fpm, betweenabout 30 fpm and about 49 fpm, between about 40 fpm and about 49 fpm,and about 49 fpm.

The above examples show the spiral driven by the drive system to movematerial upward and around the spiral. In the alternative, the spiralcan be driven by the drive system to move material downward and aroundthe spiral. This would be done by changing the attachment point of theshuffle drive to the spiral to, in effect, flip the teardrop shapedcurve so that material is moved downwards and around the spiral.

As described herein, when one or more components are described as beingconnected, joined, affixed, coupled, attached, or otherwiseinterconnected, such interconnection may be direct as between thecomponents or may be in direct such as through the use of one or moreintermediary components. Also as described herein, reference to a“member,” “component,” or “portion” shall not be limited to a singlestructural member, component, or element but can include an assembly ofcomponents, members or elements.

While the present invention has been illustrated by the description ofembodiments thereof, and while the embodiments have been described inconsiderable detail, it is not the intention of the applicants torestrict or in any way limit the scope of the invention to such details.Additional advantages and modifications will readily appear to thoseskilled in the art. For example, where components are releasably orremovably connected or attached together, any type of releasableconnection may be suitable including for example, locking connections,fastened connections, tongue and groove connections, etc. Still further,component geometries, shapes, and dimensions can be modified withoutchanging the overall role or function of the components. Therefore, theinventive concept, in its broader aspects, is not limited to thespecific details, the representative apparatus, and illustrativeexamples shown and described. Accordingly, departures may be made fromsuch details without departing from the spirit or scope of theapplicant's general inventive concept.

I claim:
 1. A vertical spiral conveyor for transporting loose materialwithout the use of vibration or oscillation, comprising: a verticalspiral fabrication comprising a spiral conveyor tray connected to avertical member that is configured to rotate about an axis of rotation;a drive arm extending from the vertical spiral fabrication; and a drivesystem for rotating the vertical spiral fabrication about the axis ofrotation, the drive system comprising a power source and a transmissioncoupled to the drive arm; and wherein the drive system generatesalternating forward and backward strokes on the drive arm that rotatethe vertical spiral fabrication clockwise and counterclockwise about theaxis of rotation to cause loose material to be conveyed around thespiral conveyor tray.
 2. The vertical spiral conveyor of claim 1,wherein the vertical spiral fabrication accelerates slowly to a maximumforward speed and then suddenly decelerates during each forward stroketo cause the loose material to slide forward on the spiral conveyortray.
 3. The vertical spiral conveyor of any of the foregoing claims,wherein the vertical spiral fabrication accelerates quickly to a maximumreturn speed during a first portion of each backward stroke to cause thespiral conveyor tray to slide from under the loose material, and whereinthe vertical spiral fabrication decelerates slowly during a secondportion of each backward stroke to prohibit backward motion of the loosematerial on the spiral conveyor tray.
 4. The vertical spiral conveyor ofany of the foregoing claims, wherein the maximum forward speed of thevertical spiral fabrication during the forward stroke and the maximumreturn speed of the vertical spiral fabrication during the backwardstroke are between about 1400 fpm and about 1500 fpm.
 5. The verticalspiral conveyor of any of the foregoing claims, wherein the maximumforward speed of the vertical spiral fabrication during the forwardstroke and the maximum return speed of the vertical spiral fabricationduring the backward stroke are about 1470 fpm.
 6. The vertical spiralconveyor of any of the foregoing claims, wherein the loose material isconveyed upward around the spiral conveyor tray to a top of the verticalspiral conveyor.
 7. The vertical spiral conveyor of any of the foregoingclaims, wherein the vertical spiral fabrication rotates between about 2degrees and about 10 degrees about the axis of rotation during eachforward and backward stroke.
 8. The vertical spiral conveyor of any ofthe foregoing claims, wherein the drive arm extends horizontally fromthe vertical member.
 9. The vertical spiral conveyor of claim 8 furthercomprising a connecting rod coupling the drive arm to the transmission.10. The vertical spiral conveyor of claim 9, wherein the connecting rodis coupled to the drive arm between about 15 inches and about 30 inchesfrom the axis of rotation and the spiral conveyor tray moves betweenabout 2.5 inches and about 6 inches during each forward and backwardstroke.
 11. The vertical spiral conveyor of any of the foregoing claims,wherein the outer diameter of the spiral conveyor tray is between about50 and about 120 inches, the inner diameter of the spiral conveyor trayis between about 30 inches and about 72 inches, and the width of thespiral conveyor tray is between about 6 inches and about 36 inches. 12.The vertical spiral conveyor of any of the foregoing claims, wherein thepitch of the spiral conveyor tray is between about 3 inches and about 12inches.
 13. The vertical spiral conveyor of any of the foregoing claimsfurther comprising a suspension unit coupling the connecting rod to thedrive arm.
 14. The vertical spiral conveyor of any of the foregoingclaims further comprising at least one mechanical accumulator attachedbetween a frame of the vertical spiral conveyor and at least one of thevertical spiral fabrication and the drive arm.
 15. The vertical spiralconveyor of any of the foregoing claims, wherein the transmission is adifferential motion transmission comprising a cam rotated by a driveshaft and a follower having a slot therein for receipt of the cam. 16.The vertical spiral conveyor of any of the foregoing claims, wherein thetransmission is a differential motion transmission comprising a driveshaft affixed to a driving member, a link, and a driven member, andwherein the link is rotatably mounted to the driving member and thedriven member.
 17. The vertical spiral conveyor of any of the foregoingclaims, wherein an output shaft of the transmission rotates from about 0degrees to about 180 degrees during each forward stroke and from about180 degrees to about 360 degrees during each backward stroke.
 18. Thevertical spiral conveyor of claim 17, wherein the output shaftaccelerates from a minimum rotation speed to a maximum rotation speedbetween about 0 degrees and about 120 degrees, decelerates from themaximum rotation speed to the minimum rotation speed between about 120degrees and about 180 degrees, accelerates from the minimum rotationspeed to the maximum rotation speed between about 180 degrees and about240 degrees, and decelerates from the maximum rotation speed to theminimum rotation speed between about 240 degrees and about 360 degrees.19. The vertical spiral conveyor of claim 18, wherein the minimumrotation speed of the output shaft is between about 30 RPM and about 60RPM and the maximum rotation speed of the output shaft is between about80 RPM and about 145 RPM.
 20. The vertical spiral conveyor of any of theforegoing claims, wherein a frame supports the vertical member of thevertical spiral fabrication.
 21. The vertical spiral conveyor of any ofthe foregoing claims, wherein a frame supports one or more sides of thevertical spiral fabrication.
 22. The vertical spiral conveyor of any ofthe foregoing claims, wherein the power source comprises a variablespeed electric motor with a speed reducer.
 23. The vertical spiralconveyor of any of the foregoing claims, wherein the vertical spiralconveyor is capable of conveying Kellogg's Corn Flakes® cereal upwardaround the spiral conveyor tray at an average speed of greater than 40feet per minute.
 24. The vertical spiral conveyor of any of theforegoing claims, wherein the vertical spiral conveyor is capable ofconveying Cheerios® cereal upward around the spiral conveyor tray at anaverage speed of greater than 40 feet per minute.
 25. A vertical spiralconveyor for transporting loose material without the use of vibration oroscillation, comprising: a vertical spiral fabrication comprising aspiral conveyor tray connected to a vertical member that is configuredto rotate about an axis of rotation; a drive arm extending horizontallyfrom the vertical member; and a drive system for rotating the verticalspiral fabrication about the axis of rotation, the drive systemcomprising a power source, a transmission, and a connecting rod couplingthe drive arm to an output shaft of the transmission; wherein the drivesystem generates alternating forward and backward strokes on the drivearm that rotate the vertical spiral fabrication clockwise andcounterclockwise about the axis of rotation to cause loose material tobe conveyed upward around the spiral conveyor tray to a top of thevertical spiral conveyor; wherein the vertical spiral fabricationaccelerates slowly with a sudden deceleration during each forward stroketo cause the loose material to slide forward on the spiral conveyortray, accelerates quickly during a first portion of each backward stroketo cause the spiral conveyor tray to slide from under the loosematerial, and decelerates slowly during a second portion of eachbackward stroke to prohibit backward motion of the loose material on thespiral conveyor tray; wherein the output shaft of the transmissionrotates from about 0 degrees to about 180 degrees during each forwardstroke and from about 180 degrees to about 360 degrees during eachbackward stroke; and wherein the output shaft accelerates from a minimumrotation speed to a maximum rotation speed between about 0 degrees andabout 120 degrees, decelerates from the maximum rotation speed to theminimum rotation speed between about 120 degrees and about 180 degrees,accelerates from the minimum rotation speed to the maximum rotationspeed between about 180 degrees and about 240 degrees, and deceleratesfrom the maximum rotation speed to the minimum rotation speed betweenabout 240 degrees and about 360 degrees.
 26. The vertical spiralconveyor of claim 25, wherein the minimum rotation speed of the outputshaft is between about 30 RPM and about 60 RPM and the maximum rotationspeed of the output shaft is between about 80 RPM and about 145 RPM. 27.A method of transporting materials without the use of vibration oroscillation, comprising: utilizing a vertical spiral conveyor, thevertical spiral conveyor comprising a vertical spiral fabrication havinga spiral conveyor tray connected to a vertical member that is configuredto rotate about an axis of rotation, a drive arm extending from thevertical spiral fabrication, and a drive system for rotating thevertical spiral fabrication about the axis of rotation, the drive systemcomprising a power source and a transmission coupled to the drive arm;and rotating the vertical spiral fabrication clockwise andcounterclockwise about the axis of rotation to cause loose material tobe conveyed around the spiral conveyor tray, wherein the drive systemgenerates alternating forward and backward strokes on the drive arm thatrotate the vertical spiral fabrication.
 28. The method of claim 27,wherein the vertical spiral fabrication accelerates slowly with a suddendeceleration during each forward stroke to cause the loose material toslide forward on the spiral conveyor tray, accelerates quickly during afirst portion of each backward stroke to cause the spiral conveyor trayto slide from under the loose material, and decelerates slowly during asecond portion of each backward stroke to prohibit backward motion ofthe loose material on the spiral conveyor tray.
 29. The method of any ofclaims 27 and 28, wherein a connecting rod couples the drive arm to anoutput shaft of the transmission, and wherein the output shaft rotatesfrom about 0 degrees to about 180 degrees during each forward stroke andfrom about 180 degrees to about 360 degrees during each backward stroke.30. The method of claim 29, wherein the output shaft accelerates from aminimum rotation speed to a maximum rotation speed between about 0degrees and about 120 degrees, decelerates from the maximum rotationspeed to the minimum rotation speed between about 120 degrees and about180 degrees, accelerates from the minimum rotation speed to the maximumrotation speed between about 180 degrees and about 240 degrees, anddecelerates from the maximum rotation speed to the minimum rotationspeed between about 240 degrees and about 360 degrees.
 31. The method ofclaim 30, wherein the minimum rotation speed of the output shaft isbetween about 30 RPM and about 60 RPM and the maximum rotation speed ofthe output shaft is between about 80 RPM and about 145 RPM.